US10610223B2 - Surgical instrument with stowing knife blade - Google Patents

Abstract

A surgical instrument with a stowing knife blade includes an elongated shaft, an end effector coupled to the shaft and including two opposed jaws, a housing included in one of the jaws, a first member mounted in the housing and movable distally, a knife pivotally coupled with the first member, and a second member. The knife is configured to cut when advanced distally. The first and second members are moved distally at the same rate during a cutting motion of the knife and the second member blocks a rotation of the knife relative to the first member during the cutting motion of the knife. After moving through the first distance, relative movement between the first and second members occurs so as to permit or induce the previously blocked rotation of the knife so that the knife can be stowed.

Description

The present application is a Continuation of U.S. Ser. No. 14/629,748 filed Feb. 24, 2015 (now U.S. Pat. No. 9,757,125); which is a Divisional of U.S. Ser. No. 13/662,382 filed Oct. 26, 2012 (now U.S. Pat. No. 8,991,678); which claims the benefit of U.S. Provisional Application No. 61/560,225 filed Nov. 15, 2011; the full disclosures which are incorporated herein by reference in their entirety for all purposes.

BACKGROUND

Minimally invasive surgical techniques are aimed at reducing the amount of extraneous tissue that is damaged during diagnostic or surgical procedures, thereby reducing patient recovery time, discomfort, and deleterious side effects. As a consequence, the average length of a hospital stay for standard surgery may be shortened significantly using minimally invasive surgical techniques. Also, patient recovery times, patient discomfort, surgical side effects, and time away from work may also be reduced with minimally invasive surgery.

A common form of minimally invasive surgery is endoscopy, and a common form of endoscopy is laparoscopy, which is minimally invasive inspection and surgery inside the abdominal cavity. In standard laparoscopic surgery, a patient's abdomen is insufflated with gas, and cannula sleeves are passed through small (approximately one-half inch or less) incisions to provide entry ports for laparoscopic instruments.

Laparoscopic surgical instruments generally include an endoscope (e.g., laparoscope) for viewing the surgical field and tools for working at the surgical site. The working tools are typically similar to those used in conventional (open) surgery, except that the working end or end effector of each tool is separated from its handle by an extension tube (also known as, e.g., an instrument shaft or a main shaft). The end effector can include, for example, a clamp, grasper, scissor, stapler, cautery tool, linear cutter, or needle holder.

To perform surgical procedures, the surgeon passes working tools through cannula sleeves to an internal surgical site and manipulates them from outside the abdomen. The surgeon views the procedure from a monitor that displays an image of the surgical site taken from the endoscope. Similar endoscopic techniques are employed in, for example, arthroscopy, retroperitoneoscopy, pelviscopy, nephroscopy, cystoscopy, cisternoscopy, sinoscopy, hysteroscopy, urethroscopy, and the like.

Minimally invasive telesurgical robotic systems are being developed to increase a surgeon's dexterity when working on an internal surgical site, as well as to allow a surgeon to operate on a patient from a remote location (outside the sterile field). In a telesurgery system, the surgeon is often provided with an image of the surgical site at a control console. While viewing a three dimensional image of the surgical site on a suitable viewer or display, the surgeon performs the surgical procedures on the patient by manipulating master input or control devices of the control console. Each of the master input devices controls the motion of a servo-mechanically actuated/articulated surgical instrument. During the surgical procedure, the telesurgical system can provide mechanical actuation and control of a variety of surgical instruments or tools having end effectors that perform various functions for the surgeon, for example, holding or driving a needle, grasping a blood vessel, dissecting tissue, or the like, in response to manipulation of the master input devices.

Manipulation and control of these end effectors is a particularly beneficial aspect of robotic surgical systems. For this reason, it is desirable to provide surgical tools that include mechanisms that provide three degrees of rotational movement of an end effector to mimic the natural action of a surgeon's wrist. Such mechanisms should be appropriately sized for use in a minimally invasive procedure and relatively simple in design to reduce possible points of failure. In addition, such mechanisms should provide an adequate range of motion to allow the end effector to be manipulated in a wide variety of positions.

Surgical clamping and cutting instruments (e.g., non-robotic linear clamping, stapling, and cutting devices, also known as surgical staplers; and electrosurgical vessel sealing devices) have been employed in many different surgical procedures. For example, a surgical stapler can be used to resect a cancerous or anomalous tissue from a gastro-intestinal tract. Many known surgical clamping and cutting devices, including known surgical staplers, have opposing jaws that clamp tissue and an articulated knife to cut the clamped tissue.

Surgical clamping and cutting instruments are often deployed into restrictive body cavities (e.g., through a cannula to inside the pelvis). Accordingly, it is desirable for the surgical clamping and cutting instrument to be both compact and maneuverable for best access to and visibility of the surgical site. Known surgical clamping and cutting instruments, however, may fail to be both compact and maneuverable. For example, known surgical staplers may lack maneuverability with respect to multiple degrees of freedom (e.g., Roll, Pitch, and Yaw) and associated desired ranges of motion. Typically, known surgical staplers have a smaller range of Pitch motion than desirable and no Yaw motion.

Additionally, surgical clamping and cutting instruments can sometimes fail to fully actuate (e.g., due to a hard obstacle blocking the knife path), potentially leaving a knife blade exposed. In such an event, it is desirable that the knife blade not be in a position that may represent a hazard with respect to removal of the surgical instrument from the surgical site. Known surgical clamping and cutting instruments, however, may fail to avoid the potential knife hazard and at the same time be compact and maneuverable.

Thus, there is believed to be a need for improved surgical clamping and cutting instruments and related methods. Such surgical clamping and cutting instruments should be compact and maneuverable, and employ a knife that does not represent a hazard with respect to removal of the surgical instrument from the surgical site when the surgical instrument fails to fully actuate.

BRIEF SUMMARY

Improved surgical clamping and cutting instruments (e.g., surgical staplers, and electrosurgical vessel sealing devices) and related methods are disclosed. Surgical clamping and cutting instruments described herein employ a proximal-to-distal knife movement, thereby orienting the knife to reduce the likelihood of unintentionally cutting tissue while removing the surgical instrument from the surgical site in the event that the surgical instrument fails to fully actuate. The surgical instruments described herein include first and second moving members that are moved toward the distal end at the same rate through a first distance to cut tissue and subsequently move relative to each other to facilitate stowing of the knife.

Thus, in one aspect, a method of articulating a knife in a surgical instrument is disclosed. The surgical instrument has a proximal end and a distal end. The method includes pivotally supporting the knife from a first member. The knife is configured to cut when the knife is moved toward the distal end. A rotation of the knife relative to the first member is blocked with the second member while moving the first member and a second member toward the distal end at the same rate. After moving the first and second members toward the distal end at the same rate, relative movement between the first and second members is generated to accomplish at least one of permitting rotation of the knife or inducing rotation of the knife.

In many embodiments, a lead screw is used to actuate the first and second members. For example, moving the first and second members towards the distal end at the same rate can include rotating a lead screw having a threaded portion operatively coupled with at least one of the first member or the second member. Generating relative movement between the first and second members can include rotating a lead screw having a threaded portion and a non-threaded portion. The threaded portion can be operatively coupled with one of the first and second members and the non-threaded portion can interface with the other of the first and second members such that rotation of the lead screw generates the relative motion between the first and second members.

Any suitable relative movement between the first and second members can be used. For example, generating relative movement between the first and second members can include moving the either one of the first member or the second member toward the distal end while preventing the other one of the first and second members from moving toward the distal end to reposition the second member relative to the first member to not block the rotation of the knife. As another example, generating relative movement between the first and second members can include moving the either one of the first member or the second member toward the proximal end while preventing the other one of the first and second members from moving toward the proximal end to reposition the second member relative to the first member to not block the rotation of the knife.

In many embodiments, the relative movement between the first and second members induces rotation of the knife relative to the first member. For example, the knife can include external gear teeth that mate with external gear teeth coupled with the second member so that the relative movement between the first and second members causes movement of the second member gear teeth relative to the knife gear teeth and corresponding rotation of the knife relative to the first member.

The knife can engage one or more features to selectively cause the knife to rotate into a desired position. For example, the method can include engaging the knife with a kick-down feature to cause the knife to rotate relative to the first member to stow a cutting edge of the knife below an upper surface of the housing. As another example, the method can include engaging the knife with a kick-down feature coupled to the second member thereby causing the knife to rotate relative to the first member to stow a cutting edge of the knife below the upper surface of the housing. As an additional example, the method can include engaging the knife with a kick-up feature to cause the knife to rotate into a cutting position during the movement of the first and second members towards the distal end at the same rate.

The method can further include additional acts performed using the surgical instrument. For example, the method can include deploying staples during the movement of the first and second members toward the distal end at the same rate.

In another aspect, a surgical instrument is disclosed. The surgical instrument includes an elongated shaft having a shaft distal end and a shaft proximal end, an end effector coupled to the shaft distal end and including two opposed jaws, a housing included in one of the jaws, a first member mounted in the housing and movable toward the housing distal end, a knife, and a second member. The second member is configured to move with the first member toward the housing distal end through a first distance. Relative movement between the first and second members occurs after the first and second members move through the first distance. The housing includes a housing proximal end, a housing distal end, an upper surface extending between the housing proximal and distal ends, a central cavity extending between the housing proximal and distal ends, and a longitudinal slot extending through the upper surface. The knife is pivotally coupled with the first member. The knife has a cutting edge configured to cut when the first member is moved toward the housing distal end. The cutting edge extends above the housing upper surface for at least a portion of the distal movement of the first member. The second member blocks a rotation of the knife relative to the first member while moving with the first member at the same rate toward the housing distal end and at least one of permits rotation of the knife after a relative movement between the first and second members or induces rotation of the knife during a relative movement between the first and second members.

In many embodiments, the surgical instrument includes a lead screw coupled with the housing for rotation relative to the housing. The lead screw is operatively coupled with at least one of the first member or the second member to drive the coupled member along at least a portion of the lead screw in response to rotation of the lead screw. For example, the lead screw can have a threaded portion and a non-threaded portion disposed distally of the threaded portion. Both the first and second members can be driven along the lead screw when the second member moves with the first member toward the housing distal end at the same rate. To generate the relative movement between the first and second members, one of the first and second members can be interfaced with the non-threaded portion and the other one of the first and second members can be interfaced with the threaded portion.

The surgical instrument can employ any suitable relative movement between the first and second members. For example, the first member or the second member can move toward the housing distal end when the second member moves relative to the first member. As another example, the first member or the second member can move toward the housing proximal end when the second member moves relative to the first member.

In many embodiments of the surgical instrument, the relative movement between the first and second members induces rotation of the knife relative to the first member. For example, the knife can include gear teeth that mate with gear teeth coupled with the second member so that the relative movement between the first and second members causes movement of the second member gear teeth relative to the knife gear teeth and corresponding rotation of the knife relative to the first member.

In many embodiments of the surgical instrument, the second member moves along with the first member until prevented from doing so. For example, the second member can be prevented from moving toward the housing distal end during a movement of the first member toward the housing distal end to reposition the second member to not block the rotation of the knife. In many embodiments, the second member is slidably mounted to the first member to move with the first member along the first distance and to not move toward the distal end during a movement of the first member toward the distal end.

The surgical instrument can include one or more features to selectively rotate the knife into a desired position. For example, the surgical instrument can include a kick-down feature coupled with the housing to cause the knife to rotate relative to the first member to stow the cutting edge of the knife below an upper surface of the housing. As another example, the surgical instrument can include a kick-down feature coupled to the second member to cause the knife to rotate relative to the first member to stow the cutting edge of the knife below an upper surface of the housing during the relative motion between the first and second members. As an additional example, the surgical instrument can include a kick-up feature coupled with the housing to cause the knife to rotate into a cutting position during the movement of the first and second members towards the distal end at the same rate.

The surgical instrument can include additional features providing additional functionality. For example, the housing can include a plurality of staple openings extending between the upper surface and the central cavity. A plurality of staples can be disposed in the staple openings, each of the staples being deployed during a movement of the first and second members toward the housing distal end at the same rate.

In another aspect, a demountably attachable cartridge of a surgical instrument is disclosed. The cartridge includes a housing demountably attachable to an end effector of the surgical instrument, a first member mounted in the housing and movable toward a distal end of the housing, a knife, and a second member. The second member is operable to move with the first member toward the distal end through a first distance. Relative movement between the first and second members occurs after the first and second members move through the first distance. The housing includes a proximal end, a distal end, an upper surface extending between the proximal and distal ends, a central cavity extending between the proximal and distal ends, and a longitudinal slot extending through the upper surface. The knife is pivotally coupled with the first member or the second member. The knife has a cutting edge configured to cut when moved toward the distal end. The cutting edge extends through the longitudinal slot for at least a portion of the movement of the first member along the lead screw. The second member blocks a rotation of the knife relative to the first member while moving with the first member. The second member at least one of permits rotation of the knife or induces rotation of the knife after a relative movement between the first and second members.

In many embodiments, the cartridge includes a lead screw coupled with the housing for rotation relative to the housing. The lead screw is operatively coupled with at least one of the first member or the second member to drive the coupled member along at least a portion of the lead screw in response to rotation of the lead screw. For example, the lead screw can have a threaded portion and a non-threaded portion disposed distally of the threaded portion. Both the first and second members can be driven along the lead screw when the second member moves with the first member toward the housing distal end at the same rate. To generate the relative movement between the first and second members, one of the first and second members can be interfaced with the non-threaded portion and the other one of the first and second members can be interfaced with the threaded portion.

In many embodiments of the cartridge, the lead screw has a threaded portion and a non-threaded portion disposed toward the distal end relative to the threaded portion. Both the first and second members are driven along the threaded portion when the second member moves with the first member toward the distal end at the same rate. One of the first and second members can interface with the threaded portion and the other one of the first and second members can interface with the non-threaded portion to generate the relative movement between the first and second members in response to a rotation of the lead screw.

The cartridge can employ any suitable relative movement between the first and second members. For example, the first member or the second member can move toward the housing distal end when the second member moves relative to the first member. As another example, the first member or the second member can move toward the housing proximal end when the second member moves relative to the first member.

In many embodiments of the cartridge, the relative movement between the first and second members induces rotation of the knife relative to the first member. For example, the knife can include gear teeth that mate with gear teeth coupled with the second member so that the relative movement between the first and second members causes movement of the second member gear teeth relative to the knife gear teeth and corresponding rotation of the knife relative to the first member.

In many embodiments of the cartridge, the second member moves along with the first member until prevented from doing so. For example, the second member can be prevented from moving toward the distal end during a movement of the first member toward the distal end to reposition the second member to not block the rotation of the knife. In many embodiments, the second member is slidably mounted to the first member to move with the first member along the first distance and to not move toward the distal end during a movement of the first member toward the distal end.

The cartridge can include one or more features to selectively rotate the knife into a desired position. For example, the cartridge can include a kick-down feature coupled with the housing to cause the knife to rotate relative to the first member to stow a cutting edge of the knife below an upper surface of the housing. As another example, the cartridge can include a kick-down feature coupled to the second member to cause the knife to rotate during a relative movement between the first and second members to stow a cutting edge of the knife below the upper surface of the housing. As an additional example, the cartridge can include a kick-up feature coupled with the housing to cause the knife to rotate into a cutting position during the movement of the second member with the first member toward the distal end at the same rate.

The cartridge can include additional features providing additional functionality. For example, the housing can include a plurality of staple openings extending between the upper surface and the central cavity. A plurality of staples can be disposed in the staple openings, each of the staples being deployed during a movement of the first and second members toward the distal end at the same rate.

For a fuller understanding of the nature and advantages of the present invention, reference should be made to the ensuing detailed description and accompanying drawings. Other aspects, objects and advantages of the invention will be apparent from the drawings and detailed description that follows.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a plan view of a minimally invasive robotic surgery system being used to perform a surgery, in accordance with many embodiments.

FIG. 2 is a perspective view of a surgeon's control console for a robotic surgery system, in accordance with many embodiments.

FIG. 3 is a perspective view of a robotic surgery system electronics cart, in accordance with many embodiments.

FIG. 4 diagrammatically illustrates a robotic surgery system, in accordance with many embodiments.

FIG. 5A is a front view of a patient side cart (surgical robot) of a robotic surgery system, in accordance with many embodiments.

FIG. 5B is a front view of a robotic surgery tool, in accordance with many embodiments.

FIG. 6 is a perspective view of a robotic surgery tool that includes an end effector having opposed clamping jaws, in accordance with many embodiments.

FIG. 7 is a perspective view of a demountably attachable cartridge of a linear stapling and cutting surgical instrument, in accordance with many embodiments.

FIG. 8 is a perspective view of the cartridge ofFIG. 7 and an attached staple retainer, in accordance with many embodiments.

FIG. 9 is a cross-sectional view showing attachment details between the cartridge ofFIG. 7 and an end effector assembly, in accordance with many embodiments.

FIG. 10 is an exploded perspective view illustrating components of the cartridge of the cartridge ofFIG. 7.

FIGS. 11A and 11B are perspective views illustrating a printed circuit assembly of the cartridge ofFIG. 7.

FIG. 12A shows a distal end of a housing of the cartridge ofFIG. 7.

FIG. 12B includes perspective views of a staple pusher of the cartridge ofFIG. 7.

FIG. 13A is a perspective view illustrating knife articulation and staple deployment related components of the cartridge ofFIG. 7.

FIG. 13B is a perspective cross-sectional view further illustrating knife articulation and staple deployment related components of the cartridge ofFIG. 7.

FIGS. 14A through 14E are schematic drawings illustrating articulation of a knife in a surgical instrument, in accordance with many embodiments.

FIG. 15A is a perspective view illustrating knife articulation and staple deployment related components of a surgical instrument, in accordance with many embodiments.

FIG. 15B is a perspective cross-sectional view illustrating a lead screw coupled with the components ofFIG. 15A, in accordance with many embodiments.

FIG. 15C is an exploded perspective view illustrating the components ofFIG. 15A.

FIG. 15D is a plan view of a slidably mounted support element of the components ofFIG. 15A.

FIG. 16 is a side view illustrating knife articulation and staple deployment related components of a surgical instrument, in accordance with many embodiments.

FIG. 17 is a side view illustrating knife articulation and staple deployment related components of a surgical instrument, in accordance with many embodiments.

FIG. 18 lists acts of a method of articulating a cutting blade in a surgical instrument, in accordance with many embodiments.

FIG. 19 lists optional acts of the method ofFIG. 18.

DETAILED DESCRIPTION

In the following description, various embodiments of the present invention will be described. For purposes of explanation, specific configurations and details are set forth in order to provide a thorough understanding of the embodiments. However, it will also be apparent to one skilled in the art that the present invention may be practiced without the specific details. Furthermore, well-known features may be omitted or simplified in order not to obscure the embodiment being described.

Minimally Invasive Robotic Surgery

Referring now to the drawings, in which like reference numerals represent like parts throughout the several views,FIG. 1 is a plan view illustration of a Minimally Invasive Robotic Surgical (MIRS)system10, typically used for performing a minimally invasive diagnostic or surgical procedure on aPatient12 who is lying down on an Operating table14. The system can include a Surgeon'sConsole16 for use by aSurgeon18 during the procedure. One ormore Assistants20 may also participate in the procedure. TheMIRS system10 can further include a Patient Side Cart22 (surgical robot) and anElectronics Cart24. ThePatient Side Cart22 can manipulate at least one removably coupled tool assembly26 (hereinafter simply referred to as a “tool”) through a minimally invasive incision in the body of thePatient12 while theSurgeon18 views the surgical site through theConsole16. An image of the surgical site can be obtained by anendoscope28, such as a stereoscopic endoscope, which can be manipulated by thePatient Side Cart22 to orient theendoscope28. TheElectronics Cart24 can be used to process the images of the surgical site for subsequent display to theSurgeon18 through the Surgeon'sConsole16. The number ofsurgical tools26 used at one time will generally depend on the diagnostic or surgical procedure and the space constraints within the operating room among other factors. If it is necessary to change one or more of thetools26 being used during a procedure, anAssistant20 may remove thetool26 from thePatient Side Cart22, and replace it with anothertool26 from atray30 in the operating room.

FIG. 2 is a perspective view of the Surgeon'sConsole16. The Surgeon'sConsole16 includes a left eye display32 and aright eye display34 for presenting theSurgeon18 with a coordinated stereo view of the surgical site that enables depth perception. TheConsole16 further includes one or moreinput control devices36, which in turn cause the Patient Side Cart22 (shown inFIG. 1) to manipulate one or more tools. Theinput control devices36 can provide the same degrees of freedom as their associated tools26 (shown inFIG. 1) to provide the Surgeon with telepresence, or the perception that theinput control devices36 are integral with thetools26 so that the Surgeon has a strong sense of directly controlling thetools26. To this end, position, force, and tactile feedback sensors (not shown) may be employed to transmit position, force, and tactile sensations from thetools26 back to the Surgeon's hands through theinput control devices36.

The Surgeon'sConsole16 is usually located in the same room as the patient so that the Surgeon may directly monitor the procedure, be physically present if necessary, and speak to an Assistant directly rather than over the telephone or other communication medium. However, the Surgeon can be located in a different room, a completely different building, or other remote location from the Patient allowing for remote surgical procedures.

FIG. 3 is a perspective view of theElectronics Cart24. TheElectronics Cart24 can be coupled with theendoscope28 and can include a processor to process captured images for subsequent display, such as to a Surgeon on the Surgeon's Console, or on another suitable display located locally and/or remotely. For example, where a stereoscopic endoscope is used, theElectronics Cart24 can process the captured images to present the Surgeon with coordinated stereo images of the surgical site. Such coordination can include alignment between the opposing images and can include adjusting the stereo working distance of the stereoscopic endoscope. As another example, image processing can include the use of previously determined camera calibration parameters to compensate for imaging errors of the image capture device, such as optical aberrations.

FIG. 4 diagrammatically illustrates a robotic surgery system50 (such asMIRS system10 ofFIG. 1). As discussed above, a Surgeon's Console52 (such as Surgeon'sConsole16 inFIG. 1) can be used by a Surgeon to control a Patient Side Cart (Surgical Robot)54 (such asPatent Side Cart22 inFIG. 1) during a minimally invasive procedure. ThePatient Side Cart54 can use an imaging device, such as a stereoscopic endoscope, to capture images of the procedure site and output the captured images to an Electronics Cart56 (such as theElectronics Cart24 inFIG. 1). As discussed above, theElectronics Cart56 can process the captured images in a variety of ways prior to any subsequent display. For example, theElectronics Cart56 can overlay the captured images with a virtual control interface prior to displaying the combined images to the Surgeon via the Surgeon'sConsole52. ThePatient Side Cart54 can output the captured images for processing outside theElectronics Cart56. For example, thePatient Side Cart54 can output the captured images to aprocessor58, which can be used to process the captured images. The images can also be processed by a combination theElectronics Cart56 and theprocessor58, which can be coupled together to process the captured images jointly, sequentially, and/or combinations thereof. One or more separate displays60 can also be coupled with theprocessor58 and/or theElectronics Cart56 for local and/or remote display of images, such as images of the procedure site, or other related images.

FIGS. 5A and 5B show aPatient Side Cart22 and asurgical tool62, respectively. Thesurgical tool62 is an example of thesurgical tools26. ThePatient Side Cart22 shown provides for the manipulation of threesurgical tools26 and animaging device28, such as a stereoscopic endoscope used for the capture of images of the site of the procedure. Manipulation is provided by robotic mechanisms having a number of robotic joints. Theimaging device28 and thesurgical tools26 can be positioned and manipulated through incisions in the patient so that a kinematic remote center is maintained at the incision to minimize the size of the incision. Images of the surgical site can include images of the distal ends of thesurgical tools26 when they are positioned within the field-of-view of theimaging device28.

Tissue Gripping End Effectors

FIG. 6 shows asurgical tool70 that includes aproximal chassis72, an instrument shaft74, and adistal end effector76 having ajaw78 that can be articulated to grip a patient tissue. The proximal chassis includes input couplers that are configured to interface with and be driven by corresponding output couplers of thePatient Side Cart22. The input couplers are drivingly coupled with drive shafts that are disposed within the instrument shaft74. The drive shafts are drivingly coupled with theend effector76.

Linear Stapling and Cutting Surgical Instruments

FIG. 7 shows a demountablyattachable cartridge100 of a linear stapling and cutting surgical instrument, in accordance with many embodiments. Thecartridge100 is configured to removably attach to a jaw of an end effector. The cartridge has aproximal end102 that is attached to the jaw of the end effector and adistal end104 disposed at a corresponding distal end of the jaw of the end effector. Thecartridge100 includes six rows ofstaple openings106, alongitudinal slot108, aproximal knife garage110, adistal knife garage112, and arotational input114. In many embodiments, a staple is disposed in each of the staple openings for deployment there from. Thelongitudinal slot108 accommodates a cutting blade of a knife member (not shown) extending there from as the knife member is moved from theproximal knife garage110 to thedistal knife garage112. In operation, the staples are deployed starting at the cartridgeproximal end102 and proceeding to the cartridgedistal end104. The cutting blade is moved to trail the stapling of the tissue to ensure that only fully stapled tissue is cut.FIG. 8 shows thecartridge100 with an attachedstaple retainer116, which is removed prior to using thecartridge100.

FIG. 9 is a cross-sectional view showing details of the attachment of thecartridge100 to anend effector118, in accordance with many embodiments. Theend effector118 includes a lower jaw120, anupper jaw122, a two degree offreedom wrist124, a rotationally-drivenclamping mechanism126, and a spring loadedcoupling128. The lower jaw120 is configured to accommodate and support thecartridge100, as well as position thecartridge100 relative to the spring loadedcoupling128. Theupper jaw122 is pivotally coupled with the lower jaw120 to articulate relative to the lower jaw120 to clamp tissue. Theupper jaw122 includes staple forming recesses configured and positioned relative to thestaple openings106 to form the staples into a “B” shape upon deployment of the staples.

The two degree offreedom wrist124 provides for attachment of theend effector118 to anelongated instrument shaft130 for articulation of theend effector118 about two orthogonal axes relative to theinstrument shaft130. Details of a suitable two degree of freedom wrist that can be used are disclosed in U.S. application Ser. No. 12/945,748, entitled “SURGICAL TOOL WITH A TWO DEGREE OF FREEDOM WRIST,” filed Nov. 12, 2010, the full disclosure of which is hereby incorporated herein by reference.

The rotationally-drivenclamping mechanism126 actuates theupper jaw122 relative to the lower jaw120 to securely clamp tissue between the upper and lower jaws. Theclamping mechanism126 is rotationally driven by afirst drive shaft132 disposed internal to theinstrument shaft130. Details of a suitable rotationally-driven clamping mechanism that can be used are disclosed in U.S. application Ser. No. 12/945,541, entitled “END EFFECTOR WITH REDUNDANT CLOSING MECHANISMS,” filed Nov. 12, 2010, the full disclosure of which is hereby incorporated herein by reference.

The spring-loadedcoupling128 rotationally couples therotational input114 of thecartridge100 with anextension shaft136, which is driven by asecond drive shaft138 disposed internal to theinstrument shaft130. The spring-loadedcoupling128 includes acoil spring140 and acoupling fitting142. In the embodiment shown, the coupling fitting142 employs a three-lobe spline receptacle that interfaces with three-sided external surfaces of therotational input114 and of theextension shaft136. The spring-loadedcoupling142 accommodates angular misalignment of the three-lobe spline that might occur when thecartridge100 is installed into theend effector118. The spring-loadedcoupling142 fully engages the three-lobe spline when rotated into angular alignment. Rotation of therotational input114 is used to translate a drive member of thecartridge100. The resulting motion of the drive member is used to deploy the staples and to distally advance a knife member to cut the clamped tissue down the center of the rows of deployed staples.

Theend effector118 includes a first universaljoint assembly148 and a second universaljoint assembly150. The first universaljoint assembly148 rotationally couples theclamping mechanism126 to thefirst drive shaft132. The second universaljoint assembly150 rotationally couples theextension shaft136 to thesecond drive shaft138. Each of the first and second universaljoint assemblies148,150 is configured to transmit torque through a range of angles suitable to the range of Pitch and Yaw of theend effector118 relative to theinstrument shaft130. Details of a suitable universal joint assembly that can be used are disclosed in U.S. application Ser. No. 12/945,740, entitled “DOUBLE UNIVERSAL JOINT,” filed Nov. 12, 2010, the full disclosure of which is hereby incorporated herein by reference.

The first andsecond drive shafts132,138 are disposed offset to the centerline of theinstrument shaft130, which may be independently rotated. Details of a suitable drive mechanism that can be used to actuate the first andsecond drive shafts132,138 are disclosed in U.S. application Ser. No. 12/945,461, entitled “MOTOR INTERFACE FOR PARALLEL DRIVE SHAFTS WITHIN AN INDEPENDENTLY ROTATING MEMBER,” filed Nov. 12, 2010, the full disclosure of which is hereby incorporated herein by reference.

FIG. 10 is an exploded perspective view illustrating components of thecartridge100. The illustrated components include theretainer116,66staples152, a printed circuit assembly (PCA)spring154, aPCA156, acartridge body158,22staple pushers160, afirst drive member144, asecond drive member145, aknife146, alead screw134, athrust washer162, alead screw nut164, and acover166. Thecartridge body158 has the66staple openings106 arranged in 6 rows, with 3 rows of thestaple openings106 being disposed on each side of thelongitudinal slot108. Theretainer116 is removably attachable to thecartridge100 and covers thestaple openings106 to retain thestaples152 prior to use of thecartridge100. Thestaple pushers160 interface with thestaples152 and slidingly interface with thecartridge body158. Thelead screw134 has a threadedportion135 and anon-threaded portion137 disposed toward thedistal end104 relative to the threadedportion137. Motion of thefirst drive member144 along the threadedportion135 of thelead screw134 results in engagement of thestaple pushers160 by distally-facing ramp surfaces176 of thefirst drive member144 to drive thestaple pushers160 up relative to thecartridge body158 to deploy thestaples152 as thefirst drive member144 moves towards thedistal end104. Theknife146 is pivotally supported from thefirst drive member144. Theknife146 includes external gear teeth that interface with external gear teeth of thesecond drive member145. Thecover166 is attached to thecartridge body158.

FIGS. 11A and 11B further illustrate thePCA156 and thePCA spring154. ThePCA spring154 interfaces with thecartridge body158 and retains thePCA156. ThePCA spring154 includes PCA spring hooks172, which latch onto thecartridge body158 to retain thePCA spring154. When thecartridge100 is attached to theend effector118, instrument pins174 of theend effector118 slide beneath and lift thePCA156, thereby electrically connecting thePCA156 with the instrument pins174 and allowing for the use of increased associated tolerances. This arrangement however is not critical, as long as the instrument pins174 make suitable contact with thePCA156. Accordingly, in some embodiments, thePCA156 can be turned on edge such that the shown chip is out of the load path. ThePCA156 can be used to electronically store identification, configuration, and/or use information associated with thecartridge100.

Thecartridge100 can be assembled using the following assembly sequence. First, with thecartridge body158 in a “bottom up” orientation, thestaple pushers160 are installed into thestaple openings106. Next, thefirst drive member144, theknife145 pivotally supported from thefirst drive member144, thesecond drive member145, thethrust washer162, and thelead screw nut164 are installed onto thelead screw134 and thelead screw nut164 is laser welded flush to the end of thelead screw134. The resulting lead screw assembly is then installed into thecartridge body158 with thefirst drive member144 and thesecond drive member145 positioned at the proximal end of thelead screw134 with suitable positioning of thesecond drive member145 relative to thefirst drive member144 to place theknife145 in a suitable orientation relative to thefirst drive member144 to cut tissue as thefirst drive member144 is advanced distally and consistent with stowing of theknife146 near the end of the travel of theknife145 toward the distal end of thecartridge body158. The resulting assembly can then be lubricated, for example, by immersing the resulting assembly into a lubricant. Next, thecover166 is installed onto thecartridge body158. Next, the assembly is flipped to a “top up” orientation and thePCA156 is installed. Next, thePCA spring154 is pushed onto thecartridge body158 until the PCA spring hooks172 latch. Next, thestaples152 are installed into thestaple openings106 and theretainer116 is then installed. Finally, data is installed into thePCA156.

FIG. 12A shows a distal end of thecartridge body158.FIG. 12B shows a top view and a perspective view of one of thestaple pushers160. As illustrated, thestaple openings106 and thestaple pushers160 have complementary shapes such that each of thestaple pushers160 is accommodated within one of thestaple openings106 for translation within thestaple opening106 in response to being driven by thedrive member144 as thedrive member144 is translated toward the cartridgedistal end104.

FIG. 13A shows anassembly200 of thecartridge100 that includes thefirst drive member144, theknife146 pivotally supported from the first drive member144 (pivot pin not shown), and thesecond drive member145.FIG. 13B shows the assembly coupled with thelead screw134. Each of thefirst drive member144 and thesecond drive member145 include internal threads that operatively couple with the threadedportion135 of thelead screw134 for simultaneous translation along thelead screw134 in response to rotation of thelead screw134. As the first andsecond drive members144,145 translate along the threadedportion135, the first andsecond drive members144,145 maintain fixed relative positioning thereby blocking rotation of theknife146 relative to thefirst drive member144 via the gearing interface between thesecond drive member145 and theknife146. Near the end of the articulation of theknife146, thefirst drive member144 is driven onto thenon-threaded portion137 of thelead screw134. Thereafter, continued rotation of thelead screw134 results in continued distal movement of thesecond drive member145 relative to thecartridge body158 with no further distal movement of thefirst drive member144 relative to thecartridge body158. The resulting relative distal movement of thesecond drive member145 relative to thefirst drive member144 rotates theknife146 relative to thefirst drive member144 to stow theknife146, for example, into thelongitudinal slot108. Theassembly200 can be configured such that adistal surface202 of thesecond drive member145 contacts aproximal surface204 of thefirst drive member144 to end the rotation of theknife146 relative to thefirst drive member144. Thereafter, continued distal movement of thesecond drive member145 along the threadedportion135 can be used to drive theassembly200 distally, for example, into thedistal garage112 of thecartridge158.

In the embodiment shown, once thefirst drive member144 is driven onto thenon-threaded portion137, continued distal movement of thesecond drive member145 along thelead screw134 is used to stow theknife146. Alternatively, after thefirst drive member144 has been driven onto thenon-threaded portion137 of thelead screw134, the direction of rotation of thelead screw134 can be reversed to move thesecond drive member145 proximally relative to thefirst drive member144 thereby rotating theknife146 relative to thefirst drive member144 to stow the knife into thelongitudinal slot108.

FIGS. 14A through 14E schematically illustrate another approach for articulating a knife in asurgical instrument210, in accordance with many embodiments. Thesurgical instrument210 includes ahousing212, alead screw134, afirst drive member214, aknife216, asecond drive member218, a knife kick-upfeature220, and a knife kick-down feature222. Thehousing212 includes aproximal end224, adistal end226, anupper surface228 extending between theproximal end224 and thedistal end226, aproximal knife garage230, adistal knife garage232, a central cavity extending between theproximal end224 and thedistal end226, and a longitudinal slot extending between theupper surface228 and the central cavity. Thelead screw134 is mounted in thehousing212 for rotation relative to thehousing212 and extends between theproximal end224 and thedistal end226 through the central cavity. Thelead screw134 has a threadedportion135 and anon-threaded portion137 disposed toward thedistal end226 relative to the threadedportion135. The first andsecond drive members214,218 have internal threads configured to couple with the threadedportion135 of thelead screw134 for translation along the threadedportion135 in response to rotation of thelead screw134. Theknife216 is pivotally supported from thefirst drive member214. The knife kick-upfeature220 and the knife kick-down feature222 are coupled with thehousing212 and have fixed positions relative to thehousing212.

FIG. 14A illustrates thesurgical instrument210 in a starting configuration in which theknife216 is disposed in theproximal garage230. Theknife216 is shown in a non-cutting orientation relative to the first drive member214 (i.e., rotated relative to a cutting orientation of the knife shown inFIG. 14B). The non-cutting orientation of the knife may enable the use of a shorter housing by reducing the initial length of the combination of thefirst drive member214 and theknife216. A shorter housing provides for a more compactsurgical instrument210, thereby enhancing maneuverability of the surgical instrument and/or visibility within a surgical site. Alternatively, theknife member216 can start in a cutting position.

From the starting configuration illustrated inFIG. 14A, rotation of thelead screw134 simultaneously drives the first andsecond drive members214,218 distally along thelead screw134. During the initial distal movement of thefirst drive member214, theknife216 contacts the kick-down feature220, which causes rotation of theknife216 relative to thefirst drive member214 into the cutting position illustrated inFIG. 14B. In the cutting position, further rotation of theknife216 relative to thefirst drive member214 is blocked by thesecond drive member218.

From the position shown inFIG. 14B, continued rotation of thelead screw134 continues to simultaneously drive the first andsecond drive members214,218 distally along thelead screw134 until thefirst drive member214 is driven onto thenon-threaded portion137 of thelead screw134 as illustrated inFIG. 14C. From the position illustrated inFIG. 14C, continued rotation of thelead screw134 continues to drive only thesecond drive member218 distally along the threadedportion134 of thelead screw134 to where thesecond drive member218 contacts thefirst drive member214 as illustrated inFIG. 14D. In the position illustrated inFIG. 14D, thesecond drive member218 is no longer positioned to block rotation of theknife216 relative to thefirst drive member214. From the position illustrated in14D, continued rotation of thelead screw134 continues to drive thesecond drive member218 along the threadedportion135 of thelead screw134, thereby also driving thefirst drive member214 along thenon-threaded portion137 of thelead screw134. By driving thefirst drive member214 along thenon-threaded portion137 of thelead screw134, theknife216 contacts the kick-down feature222, thereby ensuring that theknife216 rotates down into the longitudinal slot for stowage into thedistal knife garage232 during the continued distal motion of the first andsecond drive members214,218 to the position illustrated inFIG. 14E.

FIGS. 15A through 15D illustrate another approach for articulating a knife in a surgical instrument, in accordance with many embodiments. Aknife actuation assembly240 includes adrive member242, aknife244, and asupport member246. Thedrive member242 is internally threaded to operatively couple with alead screw134 for translation along thelead screw134 in response to rotation of thelead screw134. Thedrive member242 includes distally facingramps248 configured to interface with staple pushers to deploy staples as thedrive member242 translates along thelead screw134. Theknife244 is pivotally supported from thedrive member242 via a pivot pin (not shown). Thesupport member246 includes acentral slot250, adistal portion252, and aguide pin254. Thesupport member246 is slidably mounted in thedrive member242. Thedistal portion252 of thesupport member246 blocks a rotation of theknife244 relative to thedrive member242 when thesupport member246 is positioned relative to thedrive member242 as shown inFIGS. 15A and 15B.

Theknife actuation assembly240 is configured to maintain the configuration shown inFIGS. 15A and 15B from the start of articulation of theknife244 to near the end of articulation of theknife244, thereby maintaining theknife244 in a cutting orientation relative to thedrive member242. For example, an interference fit between thesupport member246 and thedrive member242 and/or a retaining provision (e.g., an adhesive, a frangible feature) can be used prevent inadvertent motion between thesupport member246 and thedrive member242.

Near the end of the articulation of theknife244, thesupport member246 contacts a portion of the housing that prevents further distal movement of thesupport member246 and does not prevent further distal movement of thedrive member242. Thereafter, continued rotation of thelead screw134 produces further distal movement of thedrive member242 along thelead screw134, thereby producing relative movement between thesupport member246 and thedrive member242. The relative movement repositions thesupport member246 to reposition thedistal portion252 and thecentral slot250 of thesupport member246 to permit the previously blocked rotation of theknife244 relative to thedrive member242. Once thesupport member246 has been repositioned relative to thedrive member242 to permit the previously blocked rotation of theknife244 relative to thedrive member242, continued rotation of thelead screw134 can be used to further move thedrive member242 distally along thelead screw134 such that theknife244 contacts a kick-down feature256, which ensures rotation of theknife244 relative to thedrive member242 to stow theknife244.

FIG. 16 illustrates another approach for articulating a knife in a surgical instrument, in accordance with many embodiments. Aknife actuation assembly260 includes adrive member262, aknife264, adistal member266, and alead screw134. Thedrive member262 and thedistal member264 are slidably mounted in a housing and are mounted on thelead screw134. Thedrive member262 includesinternal threads268, which are operatively coupled with thelead screw134 to move thedrive member262 along thelead screw134 in response to rotation of thelead screw134. Thedistal member266 is not operatively coupled with thelead screw134. Instead, thedistal member266 is pushed distally along thelead screw134 by thedrive member262. Thedistal member266 includes distal-facing ramp surfaces270 configured to engage staple pushers as thedistal member266 is pushed along thelead screw134 by thedrive member262. Theknife264 is pivotally supported from thedrive member262 via apivot pin272.

Theassembly260 is configured to orient theknife264 in a cutting position when thedrive member262 pushes thedistal member264 along the lead screw and to stow theknife264 when thedrive member262 is moved proximally relative to thedistal member264. Thedistal member264 includes aninterface feature274 that interfaces with theknife264 to rotationally orient theknife264 relative to thedrive member262. When thedrive member262 is pushing thedistal member264, theinterface feature272 is positioned to orient theknife264 in the cutting position and prevent rotation of theknife264 about thepivot pin272, thereby maintaining theknife264 in the cutting position. Theinterface feature272 also induces rotation of theknife264 relative to thedrive member262 when thedrive member262 is moved proximally relative to thedistal member266, thereby stowing theknife264. In operation, thelead screw134 is first rotated to advance thedrive member262 distally along thelead screw134 thereby pushing thedistal member266 along thelead screw134 to deploy staples and to maintain theknife264 in the cutting position. At the end of the distal movement of theassembly260, the direction of rotation of thelead screw134 is reversed to retract thedrive member262 proximally relative to thedistal member266, thereby causing theknife264 to rotate down into the stowed position via interaction between theinterface feature272 and theknife264.

FIG. 17 illustrates another approach for articulating a knife in a surgical instrument, in accordance with many embodiments. Aknife actuation assembly280 includes adrive member282, aknife284, a knife sled286, and alead screw134. Thedrive member282 and the knife sled286 are slidably mounted in a housing. Thedrive member282 includes internal threads operatively coupled with thelead screw134 to move thedrive member282 along thelead screw134 in response to rotation of thelead screw134. The knife sled286 is drivable distally by thedrive member282 via contact between thedrive member282 and adrive feature288 of the knife sled286. Theknife284 is pivotally supported from the knife sled286 via apivot pin290. The angular orientation of theknife284 relative to the knife sled286 is coupled with the position of thedrive member282 relative to the knife sled286 by aninterface feature292 of thedrive member282, which interfaces with theknife284 to control the angular orientation of theknife284 relative to the knife sled286. Thedrive member282 includes distal-facing ramp surfaces294 configured to engage staple pushers as thedrive member282 moves distally along thelead screw134.

Theassembly280 is configured to orient theknife284 in a cutting position when thedrive member282 pushes the knife sled286 along thelead screw134 and to stow theknife284 when thedrive member282 is moved proximally relative to the knife sled286. In operation, thelead screw134 is first rotated to advance thedrive member282 distally along thelead screw134 thereby pushing the knife sled286 in the distal direction and angularly orienting theknife284 in the cutting position. At the end of the distal movement of theassembly280, the direction of rotation of thelead screw134 is reversed to retract thedrive member282 proximally relative to the knife sled286, thereby causing theknife284 to rotate down into the stowed position via interaction between theinterface feature292 and theknife284.

Combinations and/or Modifications

The surgical instruments, assemblies, and cartridges disclosed herein can be modified and/or combined in any suitable fashion. For example, thecartridge100 described herein can be modified to employ the knife articulation approach embodied in thesurgical instrument210 described herein, to employ theknife actuation assembly240 as described herein, to employ theknife actuation assembly260 as described herein, or to employ theknife actuation assembly280 as described herein. Likewise, thesurgical instrument210 described herein can be modified to employ theknife actuation assembly200 described herein, to employ theknife actuation assembly240 as described herein, to employ theknife actuation assembly260 as described herein, or to employ theknife actuation assembly280 as described herein. And the surgical instruments, assemblies, and cartridges disclosed herein, or resulting from the foregoing modifications can be embodied in a detachably mountable cartridge such ascartridge100 and can be embodied directly into a surgical instrument without being detachably mountable to an end effector of a surgical instrument.

Knife Articulation Methods

FIG. 18 shows acts of amethod300 of articulating a knife in a surgical instrument, in accordance with many embodiments. Any suitable surgical instrument (e.g., stapling and cutting surgical instruments, electrosurgical vessel sealing devices) can be used to practice themethod300. For example, the linear stapling and cutting surgical instruments, cartridges, and related assemblies described herein can be used to practice themethod300.

In act302, a knife is pivotally supported from a first member. The knife is configured to cut when the knife member is moved toward the housing distal end. Inact304, a rotation of the knife relative to the first member is blocked by a second member while moving the first and second members toward the distal end at the same rate. Inact306, after moving the first and second members toward the distal end at the same rate, the second member is moved relative to the first member to accomplish at least one of permitting the blocked rotation of the knife or inducing the blocked rotation of the knife.

FIG. 19 shows optional acts that can be accomplished in themethod300, in accordance with many embodiments. Inoptional act308, a lead screw is rotated to move the first and second members distally along the lead screw. In optional act310, a lead screw having a threaded portion and a non-threaded portion is rotated to move the second member relative to the first member. Inoptional act312, the knife member is rotated relative to the first member in response to the relative movement between the first and second members. Inoptional act314, one of the first and second members is moved toward the distal end while the other one of the first and second members is prevented from moving toward the distal end to reposition the second member to not block the rotation of the knife. In optional act316, the knife is engaged with a kick-down feature to cause the knife to rotate to stow a cutting edge of the knife below an upper surface of a housing of the surgical instrument. In optional act318, the knife is engaged with a kick-down feature coupled with the second member to cause the knife to rotate to stow a cutting edge of the knife below an upper surface of a housing of the surgical instrument. Inoptional act320, the knife is engaged with a kick-up feature to rotate the knife into a cutting position during the movement of the first and second members toward the distal end at the same rate. Inoptional act322, staples are deployed during the movement of the first and second members toward the distal end at the same rate.

The methods disclosed herein can be employed in any suitable application. For example, the methods disclosed herein can be employed in surgical instruments, manual or powered, hand-held or robotic, directly controlled or teleoperated, for open or minimally invasive (single or multi-port) procedures.

Other variations are within the spirit of the present invention. Thus, while the invention is susceptible to various modifications and alternative constructions, certain illustrated embodiments thereof are shown in the drawings and have been described above in detail. It should be understood, however, that there is no intention to limit the invention to the specific form or forms disclosed, but on the contrary, the intention is to cover all modifications, alternative constructions, and equivalents falling within the spirit and scope of the invention, as defined in the appended claims.

The term “force” is to be construed as encompassing both force and torque (especially in the context of the following claims), unless otherwise indicated herein or clearly contradicted by context. The use of the terms “a” and “an” and “the” and similar referents in the context of describing the invention (especially in the context of the following claims) are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. The terms “comprising,” “having,” “including,” and “containing” are to be construed as open-ended terms (i.e., meaning “including, but not limited to,”) unless otherwise noted. The term “connected” is to be construed as partly or wholly contained within, attached to, or joined together, even if there is something intervening. Recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., “such as”) provided herein, is intended merely to better illuminate embodiments of the invention and does not pose a limitation on the scope of the invention unless otherwise claimed. No language in the specification should be construed as indicating any non-claimed element as essential to the practice of the invention.

Preferred embodiments of this invention are described herein, including the best mode known to the inventors for carrying out the invention. Variations of those preferred embodiments may become apparent to those of ordinary skill in the art upon reading the foregoing description. The inventors expect skilled artisans to employ such variations as appropriate, and the inventors intend for the invention to be practiced otherwise than as specifically described herein. Accordingly, this invention includes all modifications and equivalents of the subject matter recited in the claims appended hereto as permitted by applicable law. Moreover, any combination of the above-described elements in all possible variations thereof is encompassed by the invention unless otherwise indicated herein or otherwise clearly contradicted by context.

All references, including publications, patent applications, and patents, cited herein are hereby incorporated by reference to the same extent as if each reference were individually and specifically indicated to be incorporated by reference and were set forth in its entirety herein.

Claims (18)

What is claimed is:

1. A surgical instrument comprising:

an elongated shaft having a shaft distal end; and

an end effector coupled to the shaft distal end, the end effector having a first end and a second end, the end effector including:

a first member movable towards the second end of the end effector;

a knife pivotally coupled to the first member; and

a second member configured to (a) block rotation of the knife relative to the first member during a first movement of first member towards the second end of the end effector and (b) move relative to the first member to permit rotation of the knife and/or induce rotation of the knife.

2. The surgical instrument ofclaim 1, wherein the end effector includes a lead screw operatively coupled with at least one of the first member or the second member to drive the coupled member along at least a portion of the lead screw in response to rotation of the lead screw.

3. The surgical instrument ofclaim 2, wherein the lead screw has a threaded portion and a non-threaded portion disposed distally of the threaded portion, both the first and second members being driven along the lead screw when the second member moves with the first member toward the second end of the end effector at the same rate and one of the first and second members interfacing with the non-threaded portion and the other one of the first and second members interfacing with the threaded portion to generate the relative movement between the first and second members.

4. The surgical instrument ofclaim 1, wherein the first member or the second member moves toward the second end of the end effector when the second member moves relative to the first member.

5. The surgical instrument ofclaim 1, wherein the first member or the second member moves toward the second end of the end effector when the second member moves relative to the first member.

6. The surgical instrument ofclaim 1, wherein the knife includes gear teeth that mate with gear teeth coupled with the second member so that relative movement between the first and second members causes rotation of the knife relative to the first member.

7. The surgical instrument ofclaim 1, wherein the second member is slidably mounted to the first member to move with the first member along a first distance, and after the first and second members have moved through the first distance, the second member does not move toward the second end of the end effector during a movement of the first member toward the second end of the end effector.

8. The surgical instrument ofclaim 1, wherein the end effector includes a kick-up feature configured to rotate the knife into a cutting position during a movement of the knife toward the second end of the end effector.

9. The surgical instrument ofclaim 1, wherein the end effector includes a plurality of staple openings and a plurality of staples disposed in the staple openings, each of the staples being deployed during a movement of the first and second members toward the second end of the end effector.

10. A demountably attachable cartridge of a surgical instrument, the cartridge having a first end and a second end, the cartridge comprising:

a first member movable towards the second end of the cartridge;

a knife pivotally coupled to the first member; and

a second member configured to (a) block rotation of the knife relative to the first member during a first movement of first member towards the second end of the cartridge and (b) move relative to the first member to permit rotation of the knife and/or induce rotation of the knife.

11. The cartridge ofclaim 10, further comprising a lead screw operatively coupled with at least one of the first member or the second member to drive the coupled member along at least a portion of the lead screw in response to rotation of the lead screw.

12. The cartridge ofclaim 11, wherein the lead screw has a threaded portion and a non-threaded portion disposed distally of the threaded portion, both the first and second members being driven along the lead screw when the second member moves with the first member toward the second end of the cartridge at the same rate and one of the first and second members interfacing with the non-threaded portion and the other one of the first and second members interfacing with the threaded portion to generate the relative movement between the first and second members.

13. The cartridge ofclaim 10, wherein the first member or the second member moves toward the second end of the cartridge when the second member moves relative to the first member.

14. The cartridge ofclaim 10, wherein the first member or the second member moves toward the second end of the cartridge when the second member moves relative to the first member.

15. The cartridge ofclaim 10, wherein the knife includes gear teeth that mate with gear teeth coupled with the second member so that relative movement between the first and second members causes rotation of the knife relative to the first member.

16. The cartridge ofclaim 10, wherein the second member is slidably mounted to the first member to move with the first member along a first distance, and after the first and second members have moved through the first distance, the second member does not move toward the second end of the cartridge during a movement of the first member toward the second end of the cartridge.

17. The cartridge ofclaim 10, further comprising a kick-up feature configured to rotate the knife into a cutting position during a movement of the knife toward the second end of the cartridge.

18. The cartridge ofclaim 10, further comprising a plurality of staple openings and a plurality of staples disposed in the staple openings, each of the staples being deployed during a movement of the first and second members toward the second end of the cartridge.

Images